John Kravontka, CMRP, Certified Maintenance & Reliability Professional and President of Manufacturing Solutions LLC, is a training specialist, Maintenance professional, and Continuous Improvement consultant. John has more than 40 years of training, troubleshooting and rebuild/retrofit experience, with all types of machine tools and equipment. Mr. Kravontka uses many Lean manufacturing methodologies to help his clients increase their equipment productivity and reliability. His strength has been to transfer that knowledge and experience, providing immediate and sustainable results for his clients.
TOTAL PRODUCTIVE MAINTENANCE
Starting out as a Machine Tool Maintenance Apprentice, Mr. Kravontka has experience implementing Total Productive Maintenance in many different industries. A sample of results includes:
North Haven, CT: Assisted client in improving productivity of main Corrugator. In one week’s time, improved the output of Corrugator by 9%. Improved converting equipment productivity (down line) by 7% (better quality). Reduced CART changeover time by 34%. ROI for company for this work was 3 weeks.
Newark, DE: Consulted and trained a Pharmaceutical client, to assist them in improving the output of their 5 production lines. Within one year the output of those 5 lines had improved 20%. 5 years later they have sustained a 40% increase in equipment output.
Las Vegas, NV: Trained Operators and Maintenance personnel at an automotive supplier. Within two months their Haven Cut-off/Chamfer machine output was improved by 25% with a scrap reduction of 96%. PM guidelines were optimized, shims were eliminated from tooling and the equipment was modified to provide better accessibility and ease of maintenance.
Mr. Kravontka believes in “hands – on” involvement and innovative team approaches to improve equipment effectiveness. Here are a few client examples:
Milford, DE: Consulted with a Dental supply company to improve the productivity and reliability of their production filling equipment. Primary filling machine output was doubled, allowing them to eliminate a second machine, and bring another product line into the space vacated by machine number 2.
Windsor, CT: This client’s most critical piece of equipment, had its output improved by 60%, in a one week time frame. Rework and overtime costs were reduced by $65,000 per year, saving over 23,000 kilowatt hours of energy.
Mr. Kravontka and his team have developed a set of criteria (measurement system) that will assist clients in developing a maintenance strategy to improve and sustain equipment productivity/reliability.
Worcester, England: Worked with a Latch Manufacturer to improve the reliability of their main assembly machine, using PM Optimization tools and Overall Equipment Effectiveness observations. In three days time equipment output was improved by 250% and scrap reduced by 10%. 10 major air leaks were repaired, resulting in a $2,200 annual savings and the preventive maintenance guidelines were optimized for sustainability.
Wichita Falls, TX: Consulted with a Tool Manufacturer, over a two year period. Over that time frame, maintenance costs were reduced by 20% ($1.4M), while equipment reliability was being improved by an average of 10%. Enough air leaks were eliminated to be able to shut down a 200HP air compressor, saving $30,000 per year in energy costs. Counter Measures were created, designed and implemented that reduced water consumption by 46%.
Bloomfield, CT: Improved the maintenance and the effectiveness of environmental systems at this aerospace manufacturer. A more focused Maintenance PM was developed that required 1 maintenance technician 1 hour, instead of 2 technicians, 8 hours. Part of the improvement was the modification of the PM documentation. It now matched the NESHAP paperwork exactly.
Moosup, CT: Consulted and trained with an aerospace manufacturer to improve the maintenance and reliability of their production equipment. During a 4 year time frame (while the equipment output improved), maintenance costs were reduced by 10%, when typically those costs would be steadily increasing. More focused PMs, use of new predictive maintenance tools, operator input, better data and reduced use of outside contractors were all part of the formula for success.